CN102119289A

CN102119289A - Brake pad for braking systems, in particular for disc brakes

Info

Publication number: CN102119289A
Application number: CN200880130598.9A
Authority: CN
Inventors: 西蒙娜·图拉尼; 康斯坦丁·维库洛夫; 安德烈亚·加瓦齐; 马西米利亚诺·瓦尔; 保罗·瓦瓦索里; 马可·奥兰迪
Original assignee: Freni Brembo SpA
Current assignee: Lembao Public Ltd
Priority date: 2008-08-08
Filing date: 2008-12-23
Publication date: 2011-07-06
Anticipated expiration: 2028-12-23
Also published as: WO2010015897A1; EP2307759B1; JP5959853B2; JP2011530682A; US20110308899A1; WO2010015897A9; CN102119289B; CN102138022B; EP2310714A1; EP2307759A1; PL2310714T3; JP6081059B2; US8960384B2; US20110198170A1; ES2682087T3; JP6046206B2; CN102138022A; JP2011530680A; JP2016033207A; WO2010016079A1

Abstract

Brake pad for braking systems, in particular for disc brakes, consisting of friction portion (10), tribologically active, and mechanical support portion (20) which is intended to cooperate with the actuating means of a braking system. At least friction portion (10) is made from a ceramic matrix material obtained with a method comprising the following operational steps: - preparing a mixture of at least one siliconic type ceramic precursor, of particles of hard materials suitable as abrasives, of particles of substances suitable as lubricants and particles of metal materials; - hot-pressing the mixture to obtain a preformed body; - submitting the preformed body to a process of pyrolysis in order to obtain ceramisation of the preceramic binder, thus obtaining the ceramic matrix material.; The mixture comprises a catalyst suitable for favouring reticulation of said ceramic precursor during the hot-pressing step and the pyrolysis process is carried out a temperatures below 8000 DEG C. The mechanical support portion (20) may be made in ceramic matrix material as one piece with the friction portion or it may consist of a support plate provided with lightening apertures.

Description

Be used for braking system, in particular for the brake shoe of disk type braker

Technical field

The present invention relates to be used for braking system, in particular for the brake shoe of disk type braker.

Prior art

As everyone knows, be used for braking system, be made of the metal profile that is combined with friction material layer usually especially for the brake shoe of disk type braker, this friction material layer defines the friction active part of brake shoe.

Traditionally, friction material is connected with plate by glue or mechanical fixed part such as bolt or rivet.

Sheet metal plays the mechanical support friction material basically, and is suitable for bearing compression and the flexural stress that meets with usually in the break using process.

Described plate cooperates with the actuator (hydraulic piston) of braking system so that the brake shoe motion.Corresponding to plate, also make the deck (seats) that is used for brake shoe locating stud and friction material wear indicator.

As everyone knows, the weight saving of brake shoe is done one's utmost to pursue, for to be installed in can be used to racing car and thereby the braking system that stands on the high performance vehicle (for example top automobile or motorcycle) of quite big stress especially true.

Viewpoint is set out thus, attempted the structure of dunnage is transformed, but these all is limited to the brake shoe with friction portion of being made by organic material.

In fact, the brake shoe with organic material friction portion of braking system is well-known.They are built by dunnage, and dunnage is by making otch or opening or the weight saving by inserting the wire netting part therein.For example, referring to F.P. FR 2441100.

For some application-specific, also there is the brake shoe that does not have dunnage.But these pads are very expensive, be intended to be used for the braking system of racing car and made by carbon fully, and carbon itself can guarantee the on-stream mechanical stress that suitably tolerates.

As everyone knows, be used for the friction portion of the pad of high-performance braking system (being top automobile) in manufacturing, it is increasingly extensive that the use of ceramic matrix material has become.This mainly is owing to compare with the friction material that for example obtains by sintered metal powders, the ceramic matrix friction material not only has the superperformance aspect friction factor and wear resistance, and because their heat resistance has reduced the heat transfer from the brake disc to the hydraulic braking sytem.

Yet, when writing the application, also can not significantly alleviate by using the weight of the prepared pad of above-mentioned ceramic matrix friction material.

Be known that employed up to now ceramic matrix material does not have extra high anti-mechanical property.Generally speaking, in fact they be highly brittle, and can collapse suddenly to loose and be out of order.

This not only hinders the manufacturing of the pad that does not have dunnage or supporting element and be made of ceramic matrix material fully, and the metal profile that hinders operating weight to lighten.

The dunnage that operating weight alleviates can not guarantee that in fact pad has enough anti-mechanicalnesses.To this, must add to require described plate and friction material to have enough area of contact the traditional approach that described plate is fixed in friction material layer by gummed and/or mechanical fixation means.

In the ceramic matrix material that makes according to production technology, also find above-mentioned anti-mechanicalness limitation based on the polymer pyrolysis.

Be known that the polymer pyrolytic technique becomes increasingly extensive in the manufacturing of ceramic matrix material.Compare with other technology, no matter from strict work angle still from the characteristic of final products, pyrolysismethod all provides multiple advantage.

More specifically, this technology relates to a kind of following method: be higher than in controlled or inert atmosphere (for example argon gas stream) that the siliceous ceramic precursor of heating (is generally organic silicon-containing polymer under 800 ℃ the temperature, for example polysilane, Polycarbosilane, polysilazane and polysiloxane) and the mixture of suitable filler realizing conversion from organic to the inorganic polymer structure, thereby form silicon oxide carbide (SiOC) and/or silicon carbide or silicon nitride (SiC or Si ₃N ₄).Above precursor has high ceramic yield usually: the initial polymer that surpasses 50 weight % remains in the final material.

Especially compare with smelting technology, pyrolytic technique allows to control better the form of final products and the possibility of purity and work under lower temperature (800～1500 ℃).

U.S. Pat 6062351 has been described a method example making the friction material with ceramic matrix by the polymer pyrolysis.Friction material is that the mixture by one or more organic ceramic precursors (carbosil-contains silicone), reinforcing fiber (for example carbon fiber, alumina fibre, silicon nitride fiber or silicon carbide fiber) and filler (for example powder of silicon carbide, graphite, aluminium oxide, mullite, silica, titanium oxide, silicon nitride or boron nitride) begins to prepare.In mould, mixture is colded pressing then.In mould itself, heat subsequently, so that ceramic precursor polymerization and acquisition green compact.Make green compact under 800 ℃～1100 ℃ temperature, in inert atmosphere, carry out pyrolysis then.

Be known that the friction portion of ceramic matrix material itself is as the parts manufacturing at the pad that is used for disk type braker with the manufacturing of polymer pyrolytic technique.Pyrolysis step finishes, and this material passes through surfacing technology and grinding then, is connected with dunnage by gummed or mechanical means (for example, bolt or rivet) subsequently.

Friction portion can't be directly connected on the metal profile, because the temperature that reaches in the pyrolytic process (being higher than 800 ℃) will cause unacceptable plate distortion.

This limitation of current pyrolytic technique such as smelting technology means and must only finish friction material is connected with plate in pyrolysis step.Therefore, in making circulation, the specific number of assembling steps of necessary layout board and friction portion, this step can be after the grinding and surfacing step of friction portion.

Therefore, (by gummed or mechanical fixation means) connect the mode of sheet metal, and used ceramic matrix material is far from excellent anti-mechanical property, all causes remarkable restriction (if not getting rid of fully) to alleviate the possibility of pad weight by the structure of intervening plate self.

Being used to prepare the ceramic matrix friction material, is need be with low rate of heat addition operation especially for another limitation of the polymer pyrolysis of the friction portion used of preparation pad, and this is unfavorable for time schedule: independent pyrolysis step may just need tens hours.

In this regard, describe the specific embodiments of this method in the above-mentioned U. S. Patent 6062351 in detail.The pyrolysis operations cyclic design: being heated to about 150 ℃ first step with about 2 ℃/minute speed from ambient temperature, is second heating steps with 0.4 ℃/minute speed to 400 ℃ subsequently.Third and fourth heating steps is respectively to be heated to 760 ℃ and be heated to 870 ℃ with 0.46 ℃/minute speed with 0.18 ℃/minute speed.Then product is incubated about 4 hours at 870 ℃, is cooled to ambient temperature with about 1.2 ℃/minute speed subsequently.Heating steps needs about 48 hours altogether, and cooling step needs about 12 hours.

Exceeding is shaped on harmful thermal stress, and low rate of heat addition work is essential, and described thermal stress causes microscopic crack formation and final product to collapse diffusing risk owing to the release of volatile organic matter in the pyrolytic process promotes the natural phenomenon that material contracts and micropore form.

Summary of the invention

One object of the present invention thereby be to be used for braking system by providing a kind of, to eliminate above-mentioned the deficiencies in the prior art especially for the brake shoe of disk type braker; Though this brake shoe has the friction portion of ceramic matrix material at least, its weight obviously descends and does not damage anti-mechanicalness.

Another object of the present invention provides a kind of brake shoe that is used for braking system, and it is made by the ceramic matrix friction material fully, thereby does not have sheet metal, and this can not damage anti-mechanicalness.

Description of drawings

Technical characteristics of the present invention according to above-mentioned purpose can be known grasp from claims of hereinafter listing, its advantage will become more than you know by the detailed description that hereinafter provides with reference to accompanying drawing, described accompanying drawing is only by example shown one or more embodiments of the present invention, do not have restriction, wherein:

-Fig. 1 illustrates the perspective view of the brake shoe of the prepared braking system that is used for the ceramic matrix friction material of first embodiment according to the present invention;

-Fig. 1 a illustrates the planimetric map according to the brake shoe of the prepared braking system that is used for the ceramic matrix friction material of the variation scheme of the first general embodiment shown in Figure 1;

-Fig. 1 b illustrates the sectional view of the brake shoe shown in Fig. 1 a along its center line Il-Il;

-Fig. 1 c illustrates the perspective view of the brake shoe shown in Fig. 1 a;

-Fig. 2 illustrates the perspective view of the brake shoe of the prepared braking system that is used for the ceramic matrix friction material of second embodiment according to the present invention;

-Fig. 3 illustrates the exploded view that a specific embodiments according to the present invention is used to make the supporting element of brake shoe;

-Fig. 4 illustrates the planimetric map of brake shoe shown in Fig. 2 from the side opposite with the friction active side;

-Fig. 5 illustrates the sectional view of the brake shoe shown in Fig. 4 along its center line V-V;

-Fig. 6 is from illustrating planimetric map according to the prepared brake shoe of first alternate embodiment of the present invention with the opposite side of friction active side;

-Fig. 7 illustrates the sectional view of the brake shoe shown in Fig. 6 along its center line VII-VII;

-Fig. 8 is from illustrating planimetric map according to the prepared brake shoe of second alternate embodiment of the present invention with the opposite side of friction active side;

-Fig. 9 illustrates the sectional view of the brake shoe shown in Fig. 8 along its center line IX-IX;

-Figure 10 is from illustrating planimetric map according to the prepared brake shoe of the 3rd alternate embodiment of the present invention with the opposite side of friction active side;

-Figure 11 illustrates the sectional view of the brake shoe shown in Fig. 8 along its center line Xl-Xl;

-Figure 12,13 and 14 illustrates the figure according to first, second and the 3rd application mode of the inventive method respectively;

The variation tendency of the The friction coefficient brake application number of times of 3 kinds of ceramic matrix friction materials (wherein two is according to of the present invention) that the maximum temperature of-Figure 15 representative especially carrying out pyrolysis is different; With

The variation tendency of the The friction coefficient brake application number of times of the ceramic matrix friction material that-Figure 16 representative makes according to the application-specific form of the inventive method.

Describe in detail

The present invention relates to a kind ofly to be used for braking system, in particular for the brake shoe of disk type braker, this pad (friction portion at least) is made by the certain ceramics body material, and this material has so anti-mechanical property so that allows for the gross weight that alleviates brake shoe but do not damage under the anti-mechanicalness mechanical support is partly intervened.

As hereinafter describing in detail, the anti-mechanical property of above-mentioned ceramic matrix material makes that brake shoe according to the present invention has different embodiments: from made thereby do not had the brake shoe of metallic supports fully by above-mentioned material, until have the friction portion of above-mentioned ceramic matrix material and the mechanical support brake shoe of making by the loss of weight dunnage partly, and some middle embodiments between the two.

In the accompanying drawings, brake shoe integral body of the present invention is by numeral 1 expression, and friction portion and mechanical support part are represented with numeral 10 and numeral 20 respectively.

" friction portion " 10 is meant that brake shoe 1 is the active part of friction in its whole spreadable life, so this part will be worn and torn gradually by using.

" mechanical support part " 20 is meant the part that makes brake shoe 1 motion and braking force is delivered to described braking system (for example braking clamp body of disk type braker) that cooperates with actuator braking system (not shown in the drawings) brake shoe 1.Therefore supporting part 20 is the parts of mainly bearing the mechanical stress that braking system work is usually directed to.

Particularly shown in Fig. 1 and 2,, can make the deck 50 (if design) of deck 40 that is used for the brake shoe locating stud and the wear indicator that is used for friction portion 10 corresponding to supporting part 20.

As will be described in further detail below, at least the friction portion 10 used ceramic matrix friction materials of brake shoe 1 constructed in accordance not only have the excellent anti mechanical property aspect incompressible and Young's modulus, but also can make brake disc and the grey cast iron brake disc frictional fit that is suitable for composite ceramic material (CCM), thereby guarantee the excellent properties aspect wear resistance, friction and break-in (being interpreted as the time that optimum Working spent that obtains) with difference variation scheme.

Particularly about frictional behaviour, it is to be noted: compare with traditional material, friction factor mean value increases, and relevant with time-varying its stability.Also to point out, the friction co-efficient value in when beginning braking between the control panel that requires in.

According to the present invention, the ceramic matrix material that is used for the friction portion at least 10 of brake shoe 20 prepares by the method that comprises following operating procedure:

A) preparation at least a siliceous type ceramic precursor, be fit to do abrasive material the hard material particle, be fit to do the material grains of oiling agent and the mixture of metallic material particles;

B) the hot pressing mixture is to obtain precast body (green compact);

C) make precast body (green compact) experience pyrolytic process, reaching the potteryization of pre-ceramic binder, thereby obtain ceramic matrix material.

According to characterizing a first aspect of the present invention, described mixture comprises the catalyzer that is suitable for promoting in heat-press step nettedization of ceramic precursor.

The suitable catalyzer that is used for nettedization of ceramic precursor reaction (hydrolysis of polymer chain and condensation reaction) in the original mixture allows ceramic precursor nettedization very to heavens when pressing step is finished, forms network polymer structure widely thus in precast body (green compact).

Nettedization of precursor height brought a series of advantages.

The anti-mechanical property that the precast body (green compact) that heat-press step is obtained when finishing has makes its easy operating, has simplified follow-up process step.

The structure of network polymer widely that forms in the pressing step has " maintenance " ceramic precursor molecule in pyrolysis step, reduces its volatilization, the effect that improves ceramic yield thus.

This reticular structure widely (at least in part) comprises the additive granules (abrasive material, oiling agent, metal) that exists in the original mixture, they are attached in the structure itself thus, bringing advantage aspect performance (absolute value of friction factor and stability) and the wear resistance, described in hereinafter.

Although the network polymer structure is modified after chemistry-physical conversion that pyrolytic process causes widely, but still remain in the ceramic matrix material, and guarantee that final ceramic matrix material will have good anti-mechanical property equally, particularly aspect wear resistance, Young's modulus and compressibility.

According to characterizing another aspect of the present invention, pyrolytic process carries out in the temperature below 800 ℃.

The network polymer structure excellent mechanical properties of giving precast body (green compact) means that the progress degree (temperature and time) of pyrolytic process can customize as required widely.This so mean that the pottery degree of final ceramic matrix material can plan according to the behavior characteristics of final ceramic matrix material.

As hereinafter continuing, unexpectedly find to cause Properties of Friction Materials obviously to be improved in the temperature below 800 ℃ (especially 400 ℃～600 ℃) pyrolysis.

The plotted curve of Figure 15 shows braking test (function relation of friction factor and the brake operating number of times) result who carries out on 3 different disc brake pads.Curve (a) and (b) be meant 2 brake shoes constructed in accordance, wherein the highest pyrolysis temperature is respectively 500 ℃ and 700 ℃.Curve (c) is meant that the highest pyrolysis temperature is traditional pad of 900 ℃.

These curves comparison shows that the friction factor of the brake shoe that makes according to the present invention increases, and the brake shoe increase of adopting 400 ℃～600 ℃ pyrolysis temperature to make is more remarkable.

As for wear resistance, this test shows: the brake shoe that makes according to the present invention on average has bigger wear resistance: the average abrasion value of each about 0.005mm of brake operating, and the mean value of traditional brake shoe (use is higher than 800 ℃ pyrolysis temperature and makes) is the about 0.015mm of each brake operating.

Described in hereinafter,, especially carry out pyrolysis (according to the present invention) and make and to suppress stock mixture and supporting element (for example sheet metal of loss of weight) jointly 400 ℃～600 ℃ temperature below 800 ℃.Sheet metal (it can be a metal, but also can be nonmetal, for example based on the composite material of lower thermal conductivity oxide) in fact can tolerate the thermal stress that pyrolytic process produces and unacceptable thermal distortion can not take place.

Therefore can in the preparation process process of friction material, make dunnage and precast body in the operation, thereby directly combine with ceramic matrix material.Thus, needn't be in manufacturing process the final number of assembling steps of particular design friction portion and supporting element.When friction material formed the step end, therefore we obtained the easier friction material-plate unit that is used for any application of follow-up surfacing and mechanical fastening system.

As mentioned below, mixture directly having compacting jointly on the supporting element of one or more lightening holes, is formed wherein ceramic matrix material and the close-connected unit of supporting element itself.In common pressing step process, described mixture (still being fluid) infiltrates lightening hole, thereby forms mutual clamping relation (reciprocal grip relationship) between ceramic matrix material and the supporting element, as especially being indicated in Fig. 5,7 and 9.

It below is detailed description to some embodiments of brake shoe 1 according to the present invention.The preparation method of ceramic matrix material will be described then.

According to the of the present invention first general embodiment shown in Figure 1, brake shoe 1 is made by above-mentioned ceramic matrix friction material fully.Friction portion 10 and mechanical support part 20 are this material.

The conventional metals dunnage save the gross weight that has significantly alleviated brake shoe.Ceramic matrix material of the present invention has about 3kg/dm ³Proportion, and the proportion of steel (tradition is used for dunnage) is about 7.8kg/dm ³If measure-alike, the weight of brake shoe so of the present invention can be lighter by 1/3 than the brake shoe of the ceramic matrix material friction portion with conventional steel plates and known type.

About in this respect, it is to be noted when pressing step finishes (and therefore before pyrolysis step) that preformed material just has excellent conformity, the thin portion that this makes it possible to obtain, for example sharp edge of brake shoe.

The preferred suitable mold of using, with mechanical support part 20 and friction portion 10 as being made into integration.Figure 12 shows the manufacturing step figure as the brake shoe 1 of one.

Perhaps, friction portion 10 and mechanical support part 20 these two-part can be made separately, for example link by gummed and/or application machine fixed component in specific number of assembling steps then.

Advantageously, design in the particular shown in Fig. 1 a, 1b and 1c, the reinforcing member of at least one open architecture that the permission friction material corresponding to mechanical support part 20 infiltrates can be provided for the brake shoe of making by above-mentioned ceramic matrix material fully 1.

Compare with using conventional panels, the reinforcing member that inserts open architecture all can alleviate the weight of brake shoe, simultaneously the anti-mechanicalness of brake shoe itself is made bigger contribution.

Reinforcing member can cover the whole plane (shown in Fig. 1 c) of mechanical supporting part or be limited to its part, for example the plane of friction portion.

Supporting element for example can be the tabular body with lightening hole, for example reticular structure.Preferred supporting element is metal (a for example steel), can keep its shape and structure and the significantly nonmetallic material of distortion can not take place when the thermal stress that stands to suppress with pyrolytic process but can use, for example based on the composite material of the oxide with lower thermal conductivity.

Supporting element can be incorporated in the mechanical support part or places (shown in Fig. 1 c) on its outer surface, perhaps with surface that the actuator of its corresponding braking system will push on.

Preferred above-mentioned reinforcing member combines with the mechanical support part by the common compacting of heat-press step.

According to the of the present invention second general embodiment especially shown in Figure 2, only have the friction portion 10 of brake shoe 1 to make by above-mentioned ceramic matrix friction material, and mechanical support part 20 by have one or more lightening holes 25 or 26 and the dunnage 21 that combines with friction portion 10 constitute.

Preferred lightening hole 25 be located at dunnage 21 will with friction portion 10 engaging portion.

Preferred dunnage 21 is metal, for example steel.In this case, with respect to the first general embodiment of the invention described above, weight saving is not remarkable, but compared with prior art still considerable, and this is because the latter only reduces relevant with the amount of the material that constitutes plate.

Advantageously, because ceramic matrix material can make by same pyrolytic process under 400 ℃～600 ℃ temperature, so can use the dunnage (21) of nonmetallic material, for example based on the composite material of the oxide of lower thermal conductivity, the proportion of this composite material is kept form and structure and obvious distortion is not taken place less than steel and when the thermal stress that stands to suppress with pyrolytic process.

In this case, weight saving can be more remarkable, and this is because not only the amount of sheet material material reduces, and used the proportion steel low material more used than tradition.

According to especially in the preferred embodiment shown in Fig. 3 to 9, dunnage 20 comprises the peripheral frame 22 that defines inner clearance spaces 26, there be lightening hole 25 by cooperate the plate-shaped member 23 that seals above-mentioned clearance spaces 26 with framework 22 corresponding to plate-shaped member 23 with being suitable for.

In more detail, as especially seeing from Fig. 3, peripheral frame 22 comprises along the preferential formation direction of brake shoe first and second outline portions 31 respect to one another and 32.Framework 22 constitutes whole by two attachment portions 33 that link

outline portion

31 and 32 endways.

Advantageously,, can make the deck 40 that is used for the brake shoe locating stud corresponding to first portion 31, and the deck 50 that is used for the wear indicator of friction portion 10.

Preferred these two attachment portions 33 are thinner than

outline portion

31 and 32, define the deck that serves as above-mentioned plate-shaped member 23 with respect to the lower region of

outline portion

31 and 32 thus.

Preferably, in plate-shaped member 23, be evenly distributed on the whole surface of described plate-shaped member to alleviate the lightening hole 25 that dunnage 21 weight make.

In more detail, plate-shaped member 23 can constitute by having the tinsel that passes lightening hole 25, perhaps is made of wire netting.

Framework 22 and plate-shaped member 23 can or link by interlocking simply by welding, gummed, mechanical fastening system.

Preferably, as seeing from Fig. 5,7 and 9, plate-shaped member 23 will combine with the mode of the direct corresponding continuous surface of face (that is to say the face relative with the active surface that rubs) that turns round of braking system to define with framework 22 with brake shoe 1 with framework 22.

For this reason, as can seeing from Fig. 3, plate-shaped member 23 has two and supports flanks 34, and they are with respect to the stagger arrangement of principal plane position and be intended to the lower region that defines near by the attachment portion 33 of framework 22.

Advantageously, dunnage 20 can have the corresponding hardened component 24 of point that the actuator with braking system will push.

In more detail, as seeing from Fig. 6 and 8, hardened component 24 can be the annular element that links to each other with plate-shaped member 23, does not correspondingly have lightening hole.

Hardened component 24 can separate, and is designed in the embodiment shown in Fig. 6 and 7, perhaps can interconnect to form continuous structure, designed in the embodiment shown in Fig. 8 and 9.

Preferably in the heat-press step process, dunnage 21 and mixture are suppressed jointly, shown in the chart among Figure 13.Like this, still be the mixture infiltration lightening hole of fluid and the shape of taking dunnage, form closely contact.

As especially can from Fig. 4,6 and 8, seeing, with the mode in the zone that has lightening hole 25 of the friction portion 20 overlays part 20 that creates friction.

Yet, shape according to brake shoe, the friction portion that can design ceramic matrix material extends to cover the zone of wherein not designing lightening hole (structural reason) at least in part, and like that, wherein the profile of friction portion 20 is illustrated by the broken lines in the embodiment shown in Fig. 4,6 and 8.

According to the 3rd alternate embodiment of the present invention shown in Figure 10 and 11 especially, dunnage 20 only is made of above-mentioned peripheral frame 22.The clearance spaces 26 that is defined by framework 22 is the single lightening hole (as especially seeing) by the ceramic matrix material filling from Figure 11.

The surface area of preferred lightening hole 25 is at least 5mm ², even 10mm more preferably ²When only designing a lightening hole 26 (reinforcement plate is made of separately peripheral frame), the scope of the area in hole and ceramic matrix material friction portion is suitable.

In Fig. 1 c, 3,4,6 and 8, lightening hole 25 is square or rhombus.Yet hole 25 can have difformity, for example rectangle, circle, ellipse or not even regular shape.

According to a particular, the friction portion 10 of ceramic matrix material can itself be made as a unit and be connected with dunnage 21 by gummed or fixing means in specific number of assembling steps, shown in the chart of Figure 14.

Advantageously, it is contemplated that the middle embodiment between the above-mentioned first and second general embodiments, wherein the mechanical support part is by making in conjunction with the dunnage and the ceramic matrix material layer that constitute monolithic entity.

Then describe the preparation method who is used for the ceramic matrix material of brake shoe 1 according to the present invention in detail.

As mentioned above, in the most general application form, method of the present invention comprises first step, second step of hot pressing mixture and the third step of pyrolysis precast body (or molding) of at least one mixing solvent.

The step of the solvent of hybrid ceramic body material should preferably be carried out in horizontal blade formula mixer.Yet,, also can consider the mixer of other type according to the characteristic and the consumption of component to be mixed.

According to the advantageous applications scheme of the inventive method, mix the step of various components and carry out in two steps.

In the first step, the polymer ceramic precursor is mixed under the situation that does not have other component with appropriate catalyst (being used for nettedization reaction).Obtain with regard to catalyst distribution the more mixture of homogeneous thus, therefore nettedization of (after pressing step is finished) precursor launched in whole material block.

Advantageously, this first blend step carries out time enough to guarantee suitable mixing, preferred 1 to 3 minute.

In second blend step, in precursor-catalyst mixture, add all other components: abrasive material, oiling agent and metallic material.

Advantageously, this second blend step carries out time enough to guarantee suitable mixing, preferred 3 to 5 minutes.

Heat-press step preferably uses the vertical press of squeeze operation on steel mold to carry out.

Preferably, be intended to make under the situation about directly combining in friction component and the preparation process process of metal support (for example disc brake pad dunnage) at ceramic matrix material, mould should be has through hole and corresponding to the plate (or matrix) of ceramic matrix material body (for example friction portion of brake shoe) with the circumference part of the shape that forms.Plate-matrix can be provided with 1,2 or more a plurality of hole.

An end (preferred lower end is with respect to the substantially horizontal of plate-matrix in the press) of blocking through hole by the punching head that uses press to be equipped with begins operation.Then to through hole (it defines feed compartment) filling mixture.Use by brake shoe with shape and thickness then and the sheet metal of suitable selection is sealed the upper end.Suitably the position of lockplate begins compacting by the starting punching machine.With the temperature in the thermocouple measurement mould that inserts in the mould itself.

Can consider press and mould except that above-mentioned press and mould.

Combine with foregoing or separate, should preferred 250～500Kg/cm at the pressure that heat-press step is applied on the material in the mould ²

Unexpectedly find, adopt the pressure in the above predetermined range that final ceramic matrix material is had beneficial effect in the performance aspect wear resistance, friction and the break-in (being interpreted as the time that optimum Working spent that obtains).

It is to be noted that performance improvement and the pyrolytic process operational condition relevant with the pressure that adopts as above defined in the pressing process are irrelevant.

It should be appreciated that the pyrolytic process of 800 ℃ of following temperature (particularly 400 ℃～600 ℃) and employing 250～500Kg/cm ²Pressing pressure combine, final ceramic matrix material performance is had improved synergy.

With employing 250～500Kg/cm ²Pressure in conjunction with or separately, pressing step should preferably carry out under 120 ℃～150 ℃ temperature, allowing the ceramic precursor fluidisation and to reach viscosity number, thereby other component of promotion precursor and mixture closely contacts and combination.

Combine with foregoing or separate, pressing step preferably should be undertaken by the alternate cycles that applies power and release force.

According to the application-specific form of the inventive method, 3 continuous circulations that apply power and release force of pressing step design, each circulation continue about 30 seconds (15 seconds apply power, 15 seconds release forces).Then be to apply about 90～210 seconds final step of power continuously.Whole pressing step needs 3 to 5 minutes time.Press time and temperature make the ceramic precursor of abundant fluidisation be uniformly scattered onto between the particle of all parts of mould and various blending ingredients.

According to a particularly preferred mode of execution, the mixture of dunnage and precursor, catalyzer and filler is suppressed jointly, experiences pyrolysis with precast body then.

Below 800 ℃, especially carry out pyrolysis (according to the present invention) and make easy to operate and feasible 400 ℃～600 ℃ temperature.In fact, metal profile can tolerate the thermal stress that pyrolytic process produces, and unacceptable thermal distortion can not take place.

Because therefore method of the present invention can directly be attached on the green compact dunnage in the friction material preparation process, is attached on the ceramic matrix material thus.After the friction material preparation process is finished, therefore obtain the assemblying body of friction material/plate, this helps the operation of follow-up surfacing and any use mechanical fastening system.

As mentioned above, the invention is characterized in that pyrolytic process carries out in the temperature below 800 ℃.

It is to be noted, by carrying out pyrolytic process, obtain best result aspect the Properties of Friction Materials improving in the mode that reaches 400～600 ℃ of maximum temperatures.

Advantageously, pyrolytic process carried out under maximum temperature 3 to 5 hours, preferred 4 hours.

In pyrolytic process, precast body (green compact) is heated to the speed of maximum temperature from ambient temperature should be preferred 4～6 ℃/minute, preferred 5 ℃/minute.

Pyrolytic process preferably should carry out in the isothermal kiln.

Advantageously, change the oxidative phenomena of ceramicization process for fear of meeting, pyrolysis is carried out in inert atmosphere.

(general formula is SiO to be preferably formed silicon oxide carbide in ceramic matrix material _xC _y) situation under, inert atmosphere preferably should form with argon gas or nitrogen stream.

(general formula is SiO to expectation formation silicon oxynitride in ceramic matrix material _xN _y) situation under, also can consider different atmosphere, for example ammonia flow.

Application-specific form of the present invention according to shown in Fig. 1 figure makes dunnage combine with established friction material.After pyrolysis step is finished, can there be the step of precast body thickness in the grinding ceramic matrix material and as an alternative or additionally, the surfacing step of ceramic matrix.

The basic purpose of these steps is can be connected (according to the tolerance of imagination) subsequently with supporting element (for example metal profile) with the ceramic matrix material body to prepare the ceramic matrix material body in the mode that forms disc brake pad.

After finishing above grinding and/or surfacing step, this method also can consider to assemble by suitable fixed component such as bolt, rivet or glue the step of friction component and metal profile.

Advantageously, surfacing step should be carried out after friction component and dunnage number of assembling steps.

According to a particularly preferred application form of the present invention (above mention and be shown among Fig. 2), make the parts that support friction component form step and directly be attached on the friction component at friction material.

After pyrolysis step is finished, can exist precast body thickness in the grinding ceramic matrix material step and, replacedly or additionally, in the exposure of plate and the surfacing operating procedure of the body of ceramic material on the unmasked portion.

According to common application scheme of the present invention, mixture to be pressed (being expressed as weight percentage) composed as follows: 5～10% ceramic precursor and catalyzer with respect to mixture; 20%～30% abrasive material; Be not more than 60% metallic material; Be not more than 50% oiling agent.

As mentioned above, the ceramics polymer precursor is siliceous type, and especially can be selected from general formula is [R _1....2, Si (C, N, B, O) _0.5....1.5-] _nPolysilane, Polycarbosilane, polysilazane and polysiloxane.

Preferably, precursor should be selected from polysiloxane, and the replacement functional group of itself and polymer and degree of branching are irrelevant, and general formula is [RSiO _1.5-] _n, wherein R represents hydrogen or organo-functional group (alkyl, acrylic etc.).

Even more preferably, precursor should be selected from silsesquioxane, particularly poly methyl silsesquioxane.

Can consider the mixture of two or more different organic precursors.

Advantageously, the weight percentage of ceramic precursor is 6%～9% in the mixture.

Preferably, catalyzer should be selected from the organic coordination compounds with metal, and described metal is selected from the group that comprises zinc, copper, aluminium, iron, zirconium, vanadium, chromium, manganese, cobalt, nickel and titanium.

Advantageously, catalyzer is selected from acetonate/ester, beta-diketon hydrochlorate/ester and carboxylate/ester.Especially preferred catalyzer is acetylacetone,2,4-pentanedione network zinc or acetylacetone,2,4-pentanedione network zirconium.

Advantageously, catalyzer exists with stoichiometry percentage with respect to ceramic precursor, and preferred percent is 0.15%～0.3% of a mixture weight.

Preferably, used ceramic precursor and catalyzer should be powder types.But, also can use the component of other form (for example fluid).

Preferably, abrasive material comprises powdery silicon carbide.But other material that also can use its hardness to make the abrasive material effect is as boron carbide, silicon, zircon, zirconium oxide, periclase, corundum and spinel.

For the sake of simplicity, in following description, only clearly mention silicon carbide, but should not to regard as be restrictive for this at abrasive material.In fact, should expand to other abrasive material about the information of silicon carbide, for example above listed those.

Advantageously, silicon carbide is two kinds of varigrained powder types.

The ratio of the average diameter of these two kinds of powder is 9 to 11, preferred 10.

The average diameter of powder is meant the d corresponding to size distribution curve ₅₀Value.In the following description, will mention the powder definition that FEPA (European Federation of Abrasives Manufacturers) adopts.

The silicon carbide powder of distinguishing granularity means that the abrasive material of compatible dimensions can supply with all the other components of mixture.The thinnest powder and fine and glossy lubrication prescription and ceramic precursor (Binder resin) blend, and the metal granule blend of large particle powder and large-size.This helps the compacting of material.

It should be appreciated that thinner admixture of powder also is tending towards homogenizing with all the other materials, and bigger particle powder still " separates (detached) " with other component of mixture.

Therefore can see that two kinds of varigrained results obtain the abrasive material operated under the different-energy level, this performance to final friction material is favourable.When than the abrasive wear of small grain size, so than the abrasive material of coarsegrain " pulverizing " gradually.Such result is the abrasive material of constant on average existence than small grain size.

Preferably, two kinds of varigrained silicon carbide powders should have the average diameter of 1 μ m～600 μ m.

According to common application form of the present invention, big and be 0.8～1.8 than the weight ratio between the silicon carbide powder of small grain size.

As hereinafter will repeating, the disk type braker frictional fit of ceramic matrix friction material and composite ceramic material if desired is big and should be 0.8～1.2, preferred 1 than the weight ratio between the silicon carbide powder of small grain size.

Ceramic matrix friction material and grey cast iron disk type braker frictional fit should be 1.2～1.8, preferred 1.5 greatly and than the weight ratio between the silicon carbide powder of small grain size if desired.

According to an advantageous applications form of the present invention, metal granule comprises iron and/or ferro-alloy particle.

Advantageously, substitute iron and/or ferro-alloy particle or the metal granule except iron and/or ferro-alloy particle and comprise copper and/or brass particle.

Preferably, copper and brass particle separately or the percentage that exists when mixing be less than 20% of mixture weight.

Term " particle " is intended to comprise the material part of powder and fibers form.

With regard to the iron-bearing materials particle, preferred especially Steel Wool.

Preferably, the metal granule of powder type (iron, ferro-alloy, copper and/or brass) should have the average diameter less than 300 μ m, and the metal granule of fibers form (iron, ferro-alloy, copper and/or brass) should have less than the average diameter of 100 μ m with less than the length of 1mm.

According to a preferred application form of the present invention, oiling agent comprises powdery graphite.

Advantageously, substitute powdery graphite or except powdery graphite, oiling agent can comprise Powdered coke, artificial gold and/or tin.

Preferably, the percentage of graphite should be 9%～13% of mixture weight, and the weight of Powdered coke, artificial gold and tin (if consideration) should be respectively less than 35%, 10% and 5% with respect to mixture.

As in appended embodiment, describing, advantageously, Powdered coke, artificial gold and/or tin and plumbago be used in combination the minimizing content of graphite, make it lower limit near above predetermined range.

Bestly be, the average diameter of graphite and/or coke powder is 200 μ m～800 μ m, and the average diameter of artificial gold and/or tin powder is less than 100 μ m.

As mentioned above, the ceramic matrix friction material that makes with the inventive method can be used for making the brake shoe with the disk type braker frictional fit of composite ceramic material (CCM) or grey cast iron, guarantees in this optimum performance aspect two of friction co-efficient value stability and wear resistance.

If ceramic matrix material of the present invention need cooperate with the grey cast iron brake disc, the mixture of process pressing step should have following general composition (being expressed as the weight percentage with respect to mixture): 5～10% ceramic precursor and catalyzer; 20%～30% abrasive material; 25%～60% metallic material; 10%～50% oiling agent.

In more detail, according to specific implementations, have than the silicon carbide powder of coarsegrain and have and should be 1.2～1.8, preferred 1.5 than the weight ratio between the powder of small grain size.

The percentage that exists than the Powdered carbonization silicon (SiC) of coarsegrain is 12%～18% of mixture weight, and the percentage of thinner SiC powder is 6%～12% of mixture weight.

Metal granule comprises 5%～20% iron powder of mixture weight, and 5%～30% Steel Wool of mixture weight and (during consideration) its percentage are less than 20% copper and/or brass powder and/or fiber of mixture weight.

Whole particles of iron and/or ferro-alloy (powder and fiber) account for 5%～60% of mixture weight.

The graphite of preferred powder type accounts for 9%～12% of mixture weight.If consideration coke, its percentage are less than 35% of mixture weight, and the artificial gold of preferred powder type and tin (if consideration) should be respectively less than 10% and 5% of mixture weight.

When graphite was unique oiling agent, its percentage preferably should be 12% of mixture weight.The tin powder of for example adding 3 weight % makes graphite drop to 10%.

Below be the explanation to 5 specific embodiments of ceramic matrix material produced according to the present invention, described ceramic matrix material cooperates with the grey cast iron brake disc.

Embodiment 1

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

PMS MK Powder poly methyl silsesquioxane resin (CH ₃-SiO _3/2) _n(between the softened zone 50-60 ℃) mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1500 gram Powdered SiC class FEPA F36 (average diameter 525 μ m) and 1000 gram Powdered SiC class FEPA F220 (average diameter 58 μ m) then.Then add 1800 gram copper powders, 2700 gram Steel Wool, 1000 gram iron powders, add 1200 gram plumbagos at last.The mixing of second step continues about 4 minutes.

(being expressed as weight percentage) whole composed as follows of mixture: 15% Powdered SiC F36 with respect to mixture; 10% Powdered SiC F220; 18% copper powder; 27% Steel Wool; 10% iron powder; 12% plumbago; 7.8% poly methyl silsesquioxane resin; 0.2% acetylacetone,2,4-pentanedione network zinc.

The average diameter of copper powder and iron powder is respectively about 200 μ m and about 250 μ m.The average diameter of Steel Wool is about 80 μ m, and Mean length is about 0.8mm.The average diameter of plumbago is about 600 μ m.

Then, thus obtained a part of mixture experiences heat-press step to obtain nettedization of height of precast body (green compact) and silsesquioxane resins in vertical press.

The loss of weight steel plate that is made of peripheral frame and plate-shaped member of mixture and type shown in Figure 3 is suppressed jointly, and described plate-shaped member has square lightening hole, and it about 50% has about 5mm ²Surface area, all the other lightening holes have about 10mm ²Surface area.The thick about 5mm of framework, and the thick about 1mm of plate-shaped member.

In more detail, use plate (or matrix), it has the basic circumference clear opening partly for rectangle that will form shape corresponding to the ceramic matrix material body.The surface area in described hole is about 77cm ², the about 8cm of the degree of depth.

The lower end of blocking clear opening by the use punching head that press had begins operation.Fill described hole with mixture then, and seal the upper end with above-mentioned loss of weight steel plate.The amount of mixture is determined according to the final thickness of brake shoe, and is considered that subsequent compression can cause that volume reduces about 2/3.After suitable positioning plate, suppress by the starting punching machine.

Temperature in the mould (by thermocouple measurement) is maintained about 120 ℃.The maximum pressure that applies in the pressing process is about 400Kg/cm ²Design 3 continuous circulations that apply power and release force, each circulation continues about 30 seconds (15 seconds apply power, 15 seconds release forces).Then be to apply power (not discharging) continuously to reach about 150 seconds final step.Whole pressing step needs about 4 minutes.

Then be at about 0.2m in the isothermal kiln ³Pyrolysis step in the nitrogen stream of/h.With about 5 ℃/minute speed precast body is heated to about 500 ℃ from ambient temperature (25 ℃), and kept about 4 hours at 500 ℃.

The surfacing operation that the last experience of the friction portion of ceramic matrix material is intended to reduce according to the end use of brake shoe thickness.

The thickness of thus obtained brake shoe is 19.75mm (the steel plate thickness that comprises about 5mm), gross weight is about 540 grams, wherein 350 grams are the weight of the friction portion of ceramic matrix material, and remaining 190 gram is the weight of loss of weight plate with the friction material part of filling lightening hole.

Have identical shaped and heavily about 635 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 15% weight saving.

Embodiment 2

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

PMS MK Powder poly methyl silsesquioxane resin (CH ₃-SiO _3/2) _n(between the softened zone 50-60 ℃) mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1500 gram Powdered SiC class FEPAF100 (average diameter 129 μ m) and Powdered SiC class FEPA F500 (the average diameter d of 1000 grams then ₅₀12.8 μ m).Then add 1800 gram brass powders, 2700 gram Steel Wool, 900 gram iron powders, 1000 gram plumbagos, add 300 gram glass puttys at last.The mixing of second step continues about 4 minutes.

(being expressed as weight percentage) whole composed as follows of mixture: 15% Powdered SiC F100 with respect to mixture; 10% Powdered SiC F500; 18% brass powder; 27% Steel Wool; 9% iron powder; 10% plumbago; 3% glass putty; 7.8% poly methyl silsesquioxane resin; 0.2% acetylacetone,2,4-pentanedione network zinc.

The average diameter of brass powder and iron powder is respectively about 250 μ m and about 200 μ m.The average diameter of Steel Wool is about 80 μ m, and Mean length is about 0.6mm.The average diameter of plumbago and glass putty is respectively about 400 μ m and about 80 μ m.

The loss of weight steel plate that is made of peripheral frame and plate-shaped member of mixture and type shown in Figure 6 is suppressed jointly, and described plate-shaped member has the square lightening hole that 3 circular cell using the adjacent area corresponding to the braking system actuator to be provided with strengthen.About 50% lightening hole has about 5mm ²Surface area, all the other lightening holes have about 10mm ²Surface area.The thick about 5mm of framework, and the thick about 1mm of plate-shaped member.

With the temperature maintenance in the mould at about 130 ℃.The maximum pressure that applies in the pressing process is about 450Kg/cm ²Design 3 continuous circulations that apply power and release force, each circulation continues about 30 seconds (15 seconds apply power, 15 seconds release forces).Then be to apply power (not discharging) continuously to reach about 210 seconds final step.Whole pressing step needs about 5 minutes.

Then be at about 0.2m in the isothermal kiln ³Pyrolysis step in the nitrogen stream of/h.With about 6 ℃/minute speed precast body is heated to about 400 ℃ from ambient temperature (25 ℃), and kept about 4.5 hours at 400 ℃.

The thickness of thus obtained brake shoe is 19.75mm (the steel plate thickness that comprises about 5mm), gross weight is about 560 grams, wherein 350 grams are the weight of the friction portion of ceramic matrix material, and remaining 210 gram is the weight of loss of weight plate with the friction material part of filling lightening hole.

Have identical shaped and heavily about 635 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 12% weight saving.

Embodiment 3

In horizontal blade formula mixer with 780 the gram Wacker-Belsil RG100 cyclopenta silicone resin mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1300 gram Powdered SiC class FEPA F46 (average diameter 370 μ m) and Powdered SiC class FEPA F280 (the average diameter d of 800 grams then ₅₀36.5 μ m).Then add 2500 gram Steel Wool, 300 gram iron powders, 1000 gram plumbagos, 3000 gram coke powders, add 300 gram glass puttys at last.The mixing of second step continues about 4 minutes.

(being expressed as weight percentage) whole composed as follows of mixture: 13% Powdered SiC F46 with respect to mixture; 8% Powdered SiC F280; 25% Steel Wool; 3% iron powder; 10% plumbago; 30% coke powder; 3% glass putty; 7.8% contain silicone; 0.2% acetylacetone,2,4-pentanedione network zinc.

The average diameter of iron powder is about 150 μ m.The average diameter of Steel Wool is about 60 μ m, and Mean length is about 0.5mm.The average diameter of plumbago, coke powder and glass putty is respectively about 700 μ m, about 600 μ m and about 90 μ m.

Then, thus obtained a part of mixture experiences heat-press step to obtain nettedization of height of precast body (green compact) and silicone resin in vertical press.

With mixture and the thick common compacting of netted enhancing body (being similar to the tabular body shown in Fig. 3) of about 1mm with lightening hole.The surface area in about 50% hole is about 5mm ², remaining is about 10mm ²

In more detail, use the plate (or matrix) with two-part clear opening: first portion has the basic circumference part for rectangle that will form shape corresponding to friction portion, and second portion has corresponding to what supporting part will form shape and is the circumference part of rectangle substantially.Described hole has the degree of depth of about 8cm, is about 77cm corresponding to the surface area of first portion ²

The lower end of blocking clear opening by the use punching head that press had begins operation.Fill described hole with mixture then, and seal the upper end with above-mentioned netted enhancing body.The amount of mixture is determined according to the final thickness of brake shoe, and is considered that subsequent compression can cause that volume reduces about 2/3.After suitable positioning plate, suppress by the starting punching machine.

With the temperature maintenance in the mould at about 150 ℃.The maximum pressure that applies in the pressing process is about 350Kg/cm ²Design 3 continuous circulations that apply power and release force, each circulation continues about 30 seconds (15 seconds apply power, 15 seconds release forces).Then be to apply power (not discharging) continuously to reach about 210 seconds final step.Whole pressing step needs about 5 minutes.

Then be at about 0.2m in the isothermal kiln ³Pyrolysis step in the nitrogen stream of/h.With about 4 ℃/minute speed precast body is heated to about 600 ℃ from ambient temperature (25 ℃), and kept about 3.5 hours at 600 ℃.

The thickness of thus obtained brake shoe is 19.75mm (the enhancing body thickness that comprises about 1mm), gross weight is about 490 grams, wherein 350 grams are the weight of the friction portion of ceramic matrix material, and remaining 140 gram is the weight of reinforcing member with the friction material part of filling lightening hole.

Have identical shaped and heavily about 635 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 23% weight saving.

Embodiment 4

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

RG100 cyclopenta silicone resin mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1.300 gram Powdered SiC class FEPA F46 (average diameter 370 μ m) and Powdered SiC class FEPA F280 (the average diameter d of 800 grams then ₅₀36.5 μ m).Then add 2500 gram Steel Wool, 300 gram iron powders, 1000 gram plumbagos, 3000 gram coke powders, add 300 gram glass puttys at last.The mixing of second step continues about 4 minutes.

Mixture is suppressed not inserting under any reinforcing member or the dunnage.

The lower end of blocking clear opening by the use punching head that press had begins operation.Fill described hole with mixture then, and seal the upper end with the specific closing feature on the pressure setting.The amount of mixture is determined according to the final thickness of brake shoe, and is considered that subsequent compression can cause that volume reduces about 2/3.

The brake shoe of being made by ceramic matrix material experiences the surfacing operation that is intended to reduce according to the end use of brake shoe thickness at last fully.

The thickness of thus obtained brake shoe is 19.75mm (the enhancing body thickness that comprises about 1mm), and gross weight is about 470 grams, and wherein 350 grams are the weight of the friction portion of ceramic matrix material, and remaining 120 gram is the weight of supporting part.

Have identical shaped and heavily about 635 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 26% weight saving.

Embodiment 5

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

PMS MK Powder poly methyl silsesquioxane resin (CH ₃-SiO _3/2) _n(between the softened zone 50-60 ℃) mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1500 gram Powdered SiC class FEPAF36 (average diameter 525 μ m) and 1000 gram Powdered SiC class FEPA F220 (average diameter 58 μ m) then.Then add 1800 gram copper powders, 2700 gram Steel Wool, 1000 gram iron powders, add 1200 gram plumbagos at last.The mixing of second step continues about 4 minutes.

Mixture and type shown in Figure 3 are suppressed jointly by the loss of weight steel plate that peripheral frame constitutes.The thick about 5mm of this framework, and define out with single center lightening hole.

The lower end of blocking clear opening by the use punching head that press had begins operation.Fill described hole with mixture then, and seal the upper end with other closing feature that above-mentioned loss of weight steel plate and compact system have.The amount of mixture is determined according to the final thickness of brake shoe, and is considered that subsequent compression can cause that volume reduces about 2/3.After suitable positioning plate, suppress by the starting punching machine.

The thickness of thus obtained brake shoe is 19.75mm (the steel plate thickness that comprises about 5mm), gross weight is about 520 grams, wherein 350 grams are the weight of the friction portion of ceramic matrix material, and remaining 170 gram is the weight of framework with the friction material part of filling this single center lightening hole.

Have identical shaped and heavily about 635 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 18% weight saving.

Work according to ceramic matrix material of the present invention and CCM brake disc one if desired, the mixture that is used for pressing step has following general composition (being expressed as the weight percentage with respect to mixture): 5～10% ceramic precursor and catalyzer; 20%～30% abrasive material; 30%～60% metallic material; 10%～40% oiling agent.

In more detail, according to a specific mode of execution, should be 0.8～1.2, preferred 1 than the silicon carbide powder of coarsegrain with than the weight ratio between the powder of small grain size.

The percentage that exists than the Powdered carbonization silicon (SiC) of coarsegrain is 10%～15% of mixture weight.

Metal granule comprises 20%～30% Steel Wool (it can all or part ofly replace with pulverous iron) of mixture weight and its percentage copper and/or brass powder and/or fiber (if consideration) of 20% less than mixture weight.

Be different from the ceramic matrix material that cooperates with the grey cast iron brake disc, the material that is used for the CCM brake disc comprises the silicon that is selected from described particle, preferred powder type.

Advantageously, the weight percentage that exists of Si powder is 9～11% of a mixture, preferred 10%.

Si powder preferably has the average diameter less than 50 μ m.

The graphite of preferred powder type accounts for 11%～13% of mixture weight, preferred 12%.If consideration coke, its percentage are less than 20% of mixture weight, and the artificial gold of preferred powder type and tin (if consideration) should be respectively less than 10% and 5% of mixture weight.

Below be the explanation to 5 specific embodiments of ceramic matrix material produced according to the present invention, described ceramic matrix material cooperates with composite ceramic material (CCM) brake disc.

Embodiment 6

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

PMS MK Powder poly methyl silsesquioxane resin (CH ₃-SiO _3/2) _n(between the softened zone 50-60 ℃) mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1200 gram Powdered SiC class FEPAF46 (average diameter 370 μ m) and 1300 gram Powdered SiC class FEPA F280 (average diameter 36.5 μ m) then.Then add 1800 gram copper powders, 2700 gram Steel Wool, 1000 gram silica flours, add 1200 gram plumbagos at last.The mixing of second step continues about 4 minutes.

(being expressed as weight percentage) whole composed as follows of mixture: 12% Powdered SiC F46 with respect to mixture; 13% Powdered SiC F280; 18% copper powder; 27% Steel Wool; 10% silica flour; 12% plumbago; 7.8% poly methyl silsesquioxane resin; 0.2% acetylacetone,2,4-pentanedione network zinc.

The average diameter of copper powder and silica flour is respectively about 150 μ m and about 40 μ m.The average diameter of Steel Wool is about 50 μ m, and Mean length is about 0.4mm.The average diameter of plumbago is about 300 μ m.

The loss of weight steel plate that is made of peripheral frame and plate-shaped member of mixture and type shown in Figure 3 is suppressed jointly, and described plate-shaped member has square lightening hole, and about 50% lightening hole has about 5mm ²Surface area, all the other lightening holes have about 10mm ²Surface area.The thick about 5.5mm of framework, and the thick about 1mm of plate-shaped member.

In more detail, use plate (or matrix), it has the basic circumference clear opening partly for rectangle that will form shape corresponding to the ceramic matrix material body.The surface area in described hole is about 145cm ², the about 8cm of the degree of depth.

With the temperature maintenance in the mould at about 120 ℃.The maximum pressure that applies in the pressing process is about 300Kg/cm ²Design 3 continuous circulations that apply power and release force, each circulation continues about 30 seconds (15 seconds apply power, 15 seconds release forces).Then be to apply power (not discharging) continuously to reach about 90 seconds final step.Whole pressing step needs about 3 minutes.

The thickness of thus obtained brake shoe is 16.4mm (the steel plate thickness that comprises about 5.5mm), gross weight is about 860 grams, wherein 480 grams are the weight of the friction portion of ceramic matrix material, and remaining 380 gram is the weight of loss of weight plate with the friction material part of filling lightening hole.

Have identical shaped and heavily about 1180 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 27% weight saving.

Embodiment 7

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

PMS MK Powder poly methyl silsesquioxane resin (CH ₃-SiO _3/2) _n(between the softened zone 50-60 ℃) mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1200 gram Powdered SiC class FEPAF54 (average diameter 310 μ m) and Powdered SiC class FEPA F320 (the average diameter d of 1300 grams then ₅₀29.2 μ m).Then add 1000 gram silica flours, 2700 gram Steel Wool, 1200 gram plumbagos, add 1800 gram coke powders at last.The mixing of second step continues about 4 minutes.

(being expressed as weight percentage) whole composed as follows of mixture: 12% Powdered SiC F54 with respect to mixture; 13% Powdered SiC F320; 27% Steel Wool; 10% silica flour; 12% plumbago; 18% coke powder; 7.8% poly methyl silsesquioxane resin; 0.2% acetylacetone,2,4-pentanedione network zinc.

The average diameter of silica flour is about 35 μ m.The average diameter of Steel Wool is about 70 μ m, and Mean length is about 0.6mm.The average diameter of plumbago and coke powder is about 500 μ m.

The loss of weight steel plate that is made of peripheral frame and plate-shaped member of mixture and type shown in Figure 6 is suppressed jointly, and described plate-shaped member has the square lightening hole that 3 circular cell using the adjacent area corresponding to the braking system actuator to be provided with strengthen.About 50% lightening hole has about 5mm ²Surface area, all the other lightening holes have about 10mm ²Surface area.The thick about 5.5mm of framework, and the thick about 1mm of plate-shaped member.

With the temperature maintenance in the mould at about 130 ℃.The maximum pressure that applies in the pressing process is about 250Kg/cm ²Design 3 continuous circulations that apply power and release force, each circulation continues about 30 seconds (15 seconds apply power, 15 seconds release forces).Then be to apply power (not discharging) continuously to reach about 150 seconds final step.Whole pressing step needs about 4 minutes.

Then be at about 0.2m in the isothermal kiln ³Pyrolysis step in the nitrogen stream of/h.With about 5 ℃/minute speed precast body is heated to about 550 ℃ from ambient temperature (25 ℃), and kept about 4 hours at 550 ℃.

The thickness of thus obtained brake shoe is 16.4mm (the steel plate thickness that comprises about 5.5mm), gross weight is about 880 grams, wherein 480 grams are the weight of the friction portion of ceramic matrix material, and remaining 400 gram is the weight of loss of weight plate with the friction material part of filling lightening hole.

Have identical shaped and heavily about 1180 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 25% weight saving.

Embodiment 8

In horizontal blade formula mixer with 780 the gram Wacker-Belsil

RG100 cyclopenta silicone resin mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1200 gram Powdered SiC class FEPA F40 (average diameter 438 μ m) and Powdered SiC class FEPA F240 (the average diameter d of 1300 grams then ₅₀44.5 μ m).Then add 1500 gram brass powders, 2100 gram Steel Wool, 1000 gram silica flours, 1200 gram plumbagos, add 900 gram sulfuration glass puttys at last.The mixing of second step continues about 4 minutes.

(being expressed as weight percentage) whole composed as follows of mixture: 12% Powdered SiC F40 with respect to mixture; 13% Powdered SiC F240; 21% Steel Wool; 15% brass powder; 10% silica flour; 12% plumbago; 9% sulfuration glass putty; 7.8% contain silicone; 0.2% acetylacetone,2,4-pentanedione network zinc.

The average diameter of brass powder and silica flour is respectively about 200 μ m and 45 μ m.The average diameter of Steel Wool is about 80 μ m, and Mean length is about 0.8mm.The average diameter of plumbago and sulfuration glass putty is respectively about 750 μ m and about 90 μ m.

In more detail, use the plate (or matrix) with two-part clear opening: first portion has the basic circumference part for rectangle that will form shape corresponding to friction portion, and second portion has corresponding to what supporting part will form shape and is the circumference part of rectangle substantially.Described hole has the degree of depth of about 8cm, is about 145cm corresponding to the surface area of first portion ²

Then be at about 0.2m in the isothermal kiln ³Pyrolysis step in the nitrogen stream of/h.With about 5 ℃/minute speed precast body is heated to about 450 ℃ from ambient temperature (25 ℃), and kept about 4.5 hours at 450 ℃.

The thickness of thus obtained brake shoe is 16.40mm (the enhancing body thickness that comprises about 1mm), gross weight is about 760 grams, wherein 480 grams are the weight of the friction portion of ceramic matrix material, and remaining 280 gram is the weight of reinforcing member with the friction material part of filling lightening hole.

Have identical shaped and heavily about 1180 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 35.6% weight saving.

Embodiment 9

In horizontal blade formula mixer with 780 the gram Wacker-Belsil RG100 cyclopenta silicone resin mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1200 gram Powdered SiC class FEPA F40 (average diameter 438 μ m) and Powdered SiC class FEPA F240 (the average diameter d of 1300 grams then ₅₀44.5 μ m).Then add 1500 gram brass powders, 2100 gram Steel Wool, 1000 gram silica flours, 1200 gram plumbagos, add 900 gram sulfuration glass puttys at last.The mixing of second step continues about 4 minutes.

The lower end of blocking clear opening by the use punching head that press had begins operation.The amount of mixture is determined according to the final thickness of brake shoe, and is considered that subsequent compression can cause that volume reduces about 2/3.Fill described hole with mixture then, and seal the upper end with the specific closing feature that pressure setting has.

The thickness of thus obtained brake shoe is 16.4mm (the enhancing body thickness that comprises about 1mm), and gross weight is about 720 grams, and wherein 480 grams are the weight of friction portion, and remaining 240 gram is the weight of supporting part.

Have identical shaped and heavily about 1180 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 39% weight saving.

Embodiment 10

In horizontal blade formula mixer with 780 the gram Wacker-Belsil PMS MK Powder poly methyl silsesquioxane resin (CH ₃-SiO _3/2) _n(between the softened zone 50-60 ℃) mixed about 2 minutes with the Powdered acetylacetone,2,4-pentanedione network zinc of 20 grams.Add 1200 gram Powdered SiC class FEPA F46 (average diameter 370 μ m) and 1300 gram Powdered SiC class FEPA F280 (average diameter 36.5 μ m) then.Then add 1800 gram copper powders, 2700 gram Steel Wool, 1000 gram silica flours, add 1200 gram plumbagos at last.The mixing of second step continues about 4 minutes.

Mixture and type shown in Figure 3 are suppressed jointly by the loss of weight steel plate that peripheral frame constitutes.The thick about 5.5mm of this framework, and define out with single center lightening hole.

The thickness of thus obtained brake shoe is 16.4mm (the steel plate thickness that comprises about 5.5mm), gross weight is about 820 grams, wherein 480 grams are the weight of the friction portion of ceramic matrix material, and remaining 340 gram is the weight of framework with the friction material part of filling this single center lightening hole.

Have identical shaped and heavily about 1180 grams of traditional braking pad function.Therefore brake shoe of the present invention provides about 30.5% weight saving.

After pressing step is finished, confirmed that according to above embodiment 1～3 and 4～6 all ceramic matrix materials that obtain conformity is so excellent so that thin portion (for example sharp edge of brake shoe) and the operation easily that helps to realize.After pyrolysis step was finished, (anti-mechanical modulus was 12～18MPa to the good anti-mechanical property of described material performance, and Young's modulus is 5～10GPa).The averag density of material is 2.9～3.2g/cm ³Average ceramicization degree is estimated as about 70%.

Brake shoe according to the present invention is braked test, to estimate friction factor, to become the coefficient stability of function and the performance of wear resistance aspect with the brake application number of times.

This test comprises carries out brake operating 50 times to sample.

This test is to use the braking system of the brake disc with cast iron and composite ceramic material (CCM) to carry out.

The application of this test shows and cast iron brake disk and and the application of CCM brake disc between in behavior, do not have important difference.

The general average friction factor of the from the 5th to the 30th brake application of test shows is about 0.45.This value is quite variable, and wherein minimum value is about 0.42, and maximum value is about 0.48.After the 30th brake application, friction factor has decline slightly, and the mean value place about 0.42 is stable.With regard to each brake application, there is the average abrasion of about 0.005mm.

Curve among Figure 16 (abscissa is the brake application number of times, and y coordinate is a friction co-efficient value) relates to the test of carrying out in the system with cast iron brake disk and brake shoe, the friction component of wherein said pad is above embodiment's 1 a ceramic matrix material.

Therefore, the present invention significantly alleviated be used for braking system, especially for the weight of the brake shoe of disk braking system and do not damage anti-mechanicalness, wherein the friction portion at least of brake shoe is a ceramic matrix material.

Therefore, the present invention significantly reduces the operating time of the friction component of making ceramic matrix material: reduce to about 8～12 hours average time from about 60～80 hours Average Total Time (not considering the assembling with metallic supports).

Even being provided at friction factor and wear resistance aspect, the ceramic matrix friction material that the method that proposes with the present invention makes is not better than at least and the identical performance of traditional ceramics matrix friction material yet.The friction factor of material of the present invention is average out to 0.42～0.45 in fact, and traditional material has about 0.35～0.4 value.

About wear resistance, similar consideration is rational.The average abrasion value of material of the present invention is the about 0.005mm of each brake application, and traditional material is about 0.015～0.020.

The brake shoe that the various forms of implementation of identity basis the present invention are gone back in the braking test can suitably tolerate the mechanical stress that is produced by braking system actuator and braking force transmission.

And, friction component and the concrete steps of the metal profile manufacturing of having simplified brake shoe and metal profile of method of the present invention by omitting final assembling ceramic matrix material.

Thereby think that the present invention has realized its initial purpose.

Obviously, in its actual enforcement, can take and above-mentioned different form and structure, but can not therefore just get rid of in protection scope of the present invention.

In addition, all details can replace with the technical parts that are equal to, and used size, shape and material can be replaced as required.

Claims

One kind be used for braking system, especially for the brake shoe of disk type braker, the mechanical support part (20) that comprises the friction portion (10) that friction is active and be intended to cooperate with the actuator of braking system, described at least friction portion (10) are to be made by the ceramic matrix material that obtains by the method that comprises following operating procedure:

-preparation at least a siliceous type ceramic precursor, be fit to do abrasive material the hard material particle, be fit to do the material grains of oiling agent and the mixture of metallic material particles;

The described mixture of-hot pressing is to obtain precast body;

-make described precast body experience pyrolytic process realizing the potteryization of pre-ceramic binder, thus described ceramic matrix material obtained;

Described mixture is included in the catalyzer that is suitable for promoting described nettedization of ceramic precursor in the described heat-press step process, and described pyrolysis step is carried out in the temperature below 800 ℃.
2. according to the brake shoe of claim 1, wherein said pyrolytic process carries out reaching under 400～600 ℃ the maximum temperature.
3. according to the brake shoe of claim 1 or 2, wherein said pressing step carries out under 120 ℃～150 ℃ temperature.
4. according to one or multinomial brake shoe in the aforementioned claim, wherein said pressing step is at 250～500Kg/cm ²Pressure under carry out.
5. according to one or multinomial brake shoe in the aforementioned claim, wherein said mechanical support part (20) is made by described ceramic matrix material.
6. according to the brake shoe of aforementioned claim 5, wherein said mechanical support part (20) is made into integration with described friction portion (10) conduct.
7. according to the brake shoe of claim 5 or 6, comprise being combined in the described mechanical support part (20) or being arranged in reinforcing member on the outer surface of this part (20) with lightening hole.
8. according to the brake shoe of aforementioned claim 7, wherein said reinforcing member combines with described mechanical support part (20) and is used for suppressing jointly in described heat-press step.
9. according to one or multinomial brake shoe in the claim 1 to 4, wherein said mechanical support part (20) is made of dunnage 21, and described dunnage 21 has one or more lightening holes (25,26) and combines with described friction portion (10).
10. according to the brake shoe of claim 9, wherein said one or more lightening holes (25,26) be arranged on described dunnage (21) be intended to described friction portion (10) engaging portion in.
11. according to the brake shoe of claim 9 or 10, wherein said dunnage (21) is included in inside and defines the peripheral frame of clearance spaces (26) (22).
12. according to the brake shoe of aforementioned claim 11, wherein said dunnage (21) comprises the plate-shaped member (23) of the clearance spaces (26) that is suitable for sealing described peripheral frame (22), and is shaped on lightening hole (25) corresponding to described plate-shaped member (23).
13. according to one or multinomial brake shoe in the claim 9 to 12, wherein said dunnage (21) has the corresponding hardened component of point (24) with the actuator intention effect of described braking system.
14. according to one or multinomial brake shoe in the claim 9 to 13, wherein said dunnage (20) is a metal, preferred steel.
15. according to one or multinomial brake shoe in the claim 9 to 13, wherein said dunnage (20) is nonmetallic material, is preferably based on the composite material of lower thermal conductivity oxide.
16. according to one or multinomial brake shoe in the claim 1 to 4, wherein said mechanical support part (20) is made of the dunnage (21) of the nonmetallic material that combine with described friction portion (10).
17. according to one or multinomial brake shoe in the claim 9 to 16, wherein said friction portion (10) combines by the common compacting in the described heat-press step with described dunnage (21).
18. according to one or multinomial brake shoe in the claim 9 to 16, wherein said dunnage (21) combines with the described friction portion (10) of ceramic matrix material after described pyrolysis step.
19. according to each brake shoe in the aforementioned claim, wherein said mixture comprises the ceramic precursor of 5～10 weight % and catalyzer, 20%～30% abrasive material, the metallic material less than 60% and less than 50% oiling agent.
20. according to each brake shoe in the aforementioned claim, wherein said at least a ceramic precursor is selected from polysiloxane, is preferably selected from silsesquioxane.
21. according to each brake shoe in the aforementioned claim, wherein said catalyzer is selected from the organic coordination compounds with metal, described metal is selected from the group that comprises zinc, copper, aluminium, iron, zirconium, vanadium, chromium, manganese, cobalt, nickel and titanium, and described organic compound is preferably selected from acetonate/ester, beta-diketon hydrochlorate/ester and carboxylate/ester.
22. according to each brake shoe in the aforementioned claim, wherein said abrasive grain is the powder of silicon carbide, boron carbide, silicon, zircon, zirconium oxide, periclase, corundum or spinel.
23. according to each brake shoe in the aforementioned claim, wherein said abrasive grain exists as two kinds of varigrained powder, the ratio of the average diameter of these two kinds of powder is 9～11.
24., wherein have described two kinds of varigrained abrasive powders and have the average diameter of 1 μ m～600 μ m according to the brake shoe of aforementioned claim 23.
25., wherein have than the abrasive powders of coarsegrain and to have than the weight ratio between the powder of small grain size be 0.8～1.8 according to the brake shoe of claim 23 or 24.
26. according to each brake shoe in the aforementioned claim, wherein said metal granule comprises particle, copper particle, brass particle and/or the silicon grain of iron and/or ferro-alloy.
27. according to each brake shoe in the aforementioned claim, wherein all particles of copper and brass separately or the percentage when mixing less than 20 weight % of described mixture.
28. according to each brake shoe in the aforementioned claim, wherein said metal granule can exist with powder type and/or fibers form.
29. according to each brake shoe in the aforementioned claim, wherein the described metal granule of powder type has the average diameter less than 300 μ m.
30. according to each brake shoe in the aforementioned claim, wherein the average diameter of the described metal granule of fibers form is less than 100 μ m, length is less than 1mm.
31. according to each brake shoe in the aforementioned claim, wherein said lubricant particle comprises plumbago, coke powder, sulfuration glass putty and/or glass putty.
32. according to each brake shoe in the aforementioned claim, wherein said graphite exists with the percentage of the 9 weight %～13 weight % of described mixture.
33. according to each brake shoe in the aforementioned claim, wherein said coke powder exists with the percentage less than 35 weight % of described mixture.
34. according to each brake shoe in the aforementioned claim, the average diameter of the powder of wherein said graphite and/or coke is 200 μ m～800 μ m.
35. according to each brake shoe in the aforementioned claim, wherein said sulfuration glass putty exists with the percentage less than 10 weight % of described mixture.
36. according to each brake shoe in the aforementioned claim, wherein said glass putty exists with the percentage less than 5%.
37. according to each brake shoe in the aforementioned claim, the average diameter of wherein said sulfuration glass putty and/or glass putty is less than 100 μ m.